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DMLS AlSi10Mg Aluminum vs. Magnesium AZ91D

Compare DMLS AlSi10Mg Aluminum vs. Magnesium AZ91D strength, stiffness, weight and thermal properties.

DMLS AlSi10Mg Aluminum3D printed metal (DMLS)
Magnesium AZ91DCast
MechanicalDMLS AlSi10Mg AluminumMagnesium AZ91D
Yield strength270MPa11.8x stronger150MPa2
Ultimate tensile strength450MPa11.96x stronger230MPa2
Elongation at break10.2%13.4x more ductile3%2
Young's modulus (stiffness)72GPa31.6x stiffer45GPa2
Density2,670kg/m³41,810kg/m³248% lighter
Strength to weight101kN·m/kg22% higher82.9kN·m/kg
Stiffness to weight27MN·m/kg8% higher24.9MN·m/kg
Poisson's ratiobase material0.335base material0.355
Shear modulus27.1GPa1.62x stiffer in shear16.7GPa
Bulk modulus70.6GPa41% higher50GPa
Speed of sound5,193m/s4% faster4,986m/s
1k10k0.1110100Density (kg/m³)Young's modulus (GPa)Plastic PLAPlastic PETGPlastic ABSPlastic TPUPlastic NylonWoodAluminumSteelIronTitaniumSteel AISI 1018Stainless Steel 304Stainless Steel 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110Copper C10100Copper C12200GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless Steel 303Stainless Steel 17-4PHAluminum 2024-T351Aluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PolycarbonateFDM PAHT-CFFDM HIPSSLA Resin StandardSLA Resin Tough 2000SLS PA12 NylonDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelConcretePCB Laminate FR-4SiliconCeramic Alumina 96%Ceramic Aluminum NitrideAluminum A380Aluminum 6063-T6Aluminum 1100-OAluminum 3003-OAluminum ADC12Solder SAC305Plastic PBT GF30Plastic PPS GF40Plastic LCP GF30DMLS AlSi10Mg AluminumMagnesium AZ91D
Stiffness against densityHigher and further left: stiffer for its weight
1k10k101001kDensity (kg/m³)Yield strength (MPa)Plastic PLAPlastic PETGPlastic ABSPlastic TPUPlastic NylonRubberWoodAluminumSteelIronTitaniumSteel AISI 1018Stainless Steel 304Stainless Steel 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110Copper C10100Copper C12200GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless Steel 303Stainless Steel 17-4PHAluminum 2024-T351Aluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic PTFEPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PolycarbonateFDM PAHT-CFFDM HIPSSLA Resin StandardSLA Resin Tough 2000SLA Resin Elastic 50ASLS PA12 NylonDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelBrickPCB Laminate FR-4SiliconCeramic Alumina 96%Aluminum A380Aluminum 6063-T6Aluminum 1100-OAluminum 3003-OAluminum ADC12Solder SAC305Plastic PBT GF30Plastic PPS GF40Plastic LCP GF30DMLS AlSi10Mg AluminumMagnesium AZ91D
Strength against densityHigher and further left: stronger for its weight
ThermalDMLS AlSi10Mg AluminumMagnesium AZ91D
Thermal conductivity110W/m·K11.53x more heat through a fin72W/m·K2
Thermal expansionmean 25-100 °C20µm/m·K125% less25µm/m·K2
100 mm part over a 50 °C swing100µm growth25% less125µm growth
Specific heatbase material963J/kg·K51,050J/kg·K2
Heats up and cools (diffusivity)42.8mm²/s13% faster37.9mm²/s
Thermal shock resistance13,819W/m2.21x more resistant6,240W/m
Melting pointnot sourcedmelting range470–595°C2
1k10k0.1110100Density (kg/m³)Thermal conductivity (W/m·K)Plastic PLAPlastic PETGPlastic ABSPlastic NylonRubberWoodAluminumSteelIronTitaniumSteel AISI 1018Stainless Steel 304Stainless Steel 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110Copper C10100Copper C12200GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless Steel 303Stainless Steel 17-4PHAluminum 2024-T351Aluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic PTFEPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PolycarbonateFDM HIPSSLA Resin StandardDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelConcreteBrickPCB Laminate FR-4SiliconCeramic Alumina 96%Ceramic Aluminum NitrideAluminum A380Aluminum 6063-T6Aluminum 1100-OAluminum 3003-OAluminum ADC12Solder SAC305Plastic PBT GF30Plastic PPS GF40Plastic LCP GF30DMLS AlSi10Mg AluminumMagnesium AZ91D
Thermal conductivity against densityHigher and further left: spreads more heat for its weight
0.111010010100Thermal conductivity (W/m·K)Thermal expansion (µm/m·K)Plastic PETGPlastic ABSPlastic NylonWoodAluminumSteelIronTitaniumSteel AISI 1018Stainless Steel 304Stainless Steel 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110Copper C10100Copper C12200GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless Steel 303Stainless Steel 17-4PHAluminum 2024-T351Aluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic PTFEPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PolycarbonateFDM HIPSSLA Resin StandardDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelConcreteBrickPlywoodPCB Laminate FR-4SiliconCeramic Alumina 96%Ceramic Aluminum NitrideAluminum A380Aluminum 6063-T6Aluminum 1100-OAluminum 3003-OAluminum ADC12Solder SAC305Plastic PBT GF30Plastic PPS GF40Plastic LCP GF30DMLS AlSi10Mg AluminumMagnesium AZ91D
Thermal expansion against thermal conductivityLower and further right: warps less when heated
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Sources5 documents: EOS GmbH, Magnesium Elektron, Renishaw, U.S. Department of Defense
DMLS AlSi10Mg Aluminum
EOS Aluminium AlSi10Mg (powder 9011-0024), EOS M 290 | 30 µm process (AlSi10Mg_FlexM291 2.01), as manufactured, horizontal; machined (turned) specimens, ISO 6892-1 B10
Magnesium AZ91D
ELEKTRON AZ91D magnesium die-casting alloy, as cast; Magnesium Elektron datasheet 475 (7/01), typical properties; Poisson from MIL-HDBK-5J for AZ91C castings.
  1. 1
    EOS Aluminium AlSi10Mg Material Data SheetEOS GmbHarchived copyDMLS AlSi10Mg Aluminum · Yield strength: typical, as manufactured, horizontalDMLS AlSi10Mg Aluminum · Ultimate tensile strength: typical, as manufactured, horizontalDMLS AlSi10Mg Aluminum · Elongation at break: typical at break, as manufactured, horizontalDMLS AlSi10Mg Aluminum · Thermal conductivity: typical, as manufactured, horizontal (ISO 22007-2)DMLS AlSi10Mg Aluminum · Thermal expansion: mean 25-100 °C, ASTM E228
  2. 2
    Elektron Die Casting Alloys (Datasheet 475)Magnesium Elektronarchived copyMagnesium AZ91D · Yield strength: typical, 0.2% tensile yield, ambient temperatureMagnesium AZ91D · Ultimate tensile strength: typical, ambient temperatureMagnesium AZ91D · Elongation at break: typical, ambient temperatureMagnesium AZ91D · Young's modulus (stiffness): typicalMagnesium AZ91D · Density: typicalMagnesium AZ91D · Thermal conductivity: typicalMagnesium AZ91D · Thermal expansion: typical, temperature range not statedMagnesium AZ91D · Specific heat: typicalMagnesium AZ91D · Melting point: melting range
  3. 3
    RenAM 500 Series Aluminium AlSi10Mg Material Data SheetRenishawDMLS AlSi10Mg Aluminum · Young's modulus (stiffness): same material and process, different machine maker: Renishaw RenAM 500, 30 µm, as built, horizontal (XY)
  4. 4
    EOS Aluminium AlSi10Mg Material Data Sheet, FlexLine, M 290 (2018)EOS GmbHarchived copyDMLS AlSi10Mg Aluminum · Density: typical part density (ISO 3369), EOS M 290, AlSi10Mg_030_FlexM291 (30 µm)
  5. 5
    MIL-HDBK-5J, Metallic Materials and Elements for Aerospace Vehicle Structures (2003)U.S. Department of DefenseDMLS AlSi10Mg Aluminum · Poisson's ratio: base material: cast Al-Si-Mg alloy 359.0 (Al-9Si-0.6Mg, closest MIL-HDBK-5J alloy to AlSi10Mg / EN AC-43000)Magnesium AZ91D · Poisson's ratio: base material: AZ91C casting (MIL-HDBK-5J handbook physical constant)DMLS AlSi10Mg Aluminum · Specific heat: base material: cast Al-Si-Mg alloy 359.0 (MIL-HDBK-5J), at 100 °C

Each number points to the document that states it, with the exact basis. Values without a number are computed from the sourced ones. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.

DMLS AlSi10Mg Aluminum is 3D printed: its properties depend on build direction and print settings; these are typical values.

Questions

Mechanical

Is DMLS AlSi10Mg Aluminum stronger than Magnesium AZ91D?

DMLS AlSi10Mg Aluminum is stronger: its yield strength is 270 MPa against 150 MPa for Magnesium AZ91D (1.8x).

Which is lighter, DMLS AlSi10Mg Aluminum or Magnesium AZ91D?

Magnesium AZ91D is lighter: 1,810 kg/m³ against 2,670 kg/m³ for DMLS AlSi10Mg Aluminum.

Which is stiffer, DMLS AlSi10Mg Aluminum or Magnesium AZ91D?

DMLS AlSi10Mg Aluminum is stiffer: Young's modulus 72 GPa against 45 GPa for Magnesium AZ91D, so the same part in DMLS AlSi10Mg Aluminum deflects less under the same load.

Which is lighter for the same job, DMLS AlSi10Mg Aluminum or Magnesium AZ91D?

For the same stiffness or strength: DMLS AlSi10Mg Aluminum is lighter for a stiff rod or tie (tension), strong rod or tie; Magnesium AZ91D is lighter for a stiff beam (bending), stiff panel or plate, strong panel or plate.

Part that must beDMLS AlSi10Mg AluminumMagnesium AZ91D
Stiff rod or tie (tension)lighter8% heavier
Stiff beam (bending)17% heavierlighter
Stiff panel or plate26% heavierlighter
Strong rod or tielighter22% heavier
Strong beamabout equalabout equal
Strong panel or plate10% heavierlighter

For the same stiffness or strength, mass scales with density over stiffness (or strength) raised to a power set by how the part is loaded: 1 for a rod in tension, 1/2 for a beam in bending, 1/3 for a panel (the standard material-selection indices).

Which is more ductile, DMLS AlSi10Mg Aluminum or Magnesium AZ91D?

DMLS AlSi10Mg Aluminum stretches further before it breaks: 10.2% elongation at break against 3% for Magnesium AZ91D.

Thermal

Which conducts heat better, DMLS AlSi10Mg Aluminum or Magnesium AZ91D?

DMLS AlSi10Mg Aluminum conducts heat better: 110 W/m·K against 72 W/m·K for Magnesium AZ91D.

Which expands less with temperature?

DMLS AlSi10Mg Aluminum expands less: 20 µm/m·K against 25 µm/m·K for Magnesium AZ91D.

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